Push bar mounting system

ABSTRACT

A push bar mounting system for mounting a push bar to vehicle&#39;s bumper without significant damage to the bumper. The system comprises a front and rear bracket mounted to an inner bumper of the vehicle and having top and bottom mounting tabs that extend away from the inner bumper. The brackets are configured to attach to the inner bumper without drilling mounting holes therein. Additionally, the mounting tabs are configured to extend through a bumper fascia that surrounds the inner bumper. As such, the bottom mounting tab extends through a grille opening in the fascia, and the upper mounting tab extends through a small horizontal opening cut out of the bumper fascia&#39;s chrome trim channel. Upon removal of the push bar from the vehicle, the opening cut in the bumper fascia can be covered by replacing the chrome trim that is mounted in the trim channel.

FIELD OF THE INVENTION

[0001] The present invention generally relates to push bars for vehiclesand more specifically to a mounting system for such a device that doesnot significantly damage the bumper of the vehicle to which the push baris mounted.

BACKGROUND OF THE INVENTION

[0002] Push bars are mounted on law enforcement vehicles to protect thefront of the vehicle while pushing stranded vehicles off the roadway.Such devices are well known and are commonly mounted to the front bumperof such vehicles. The push bar usually comprises a generally verticalmember mounted to the bumper of the vehicle. The vertical member istypically fabricated from a metallic material with the necessarystrength to support the resistance of another vehicle during pushing.Typically, the vertical member will have a rubber coating or bumperapplied to the surface that contacts the stranded vehicle. Usually, twopush bars are mounted on either side of the vehicle's front grille inorder to properly push a stranded vehicle.

[0003] In order to further protect the front of the law enforcementvehicle, the two vertical members can be interconnected by two generallyhorizontal members disposed in front the vehicle's grille and configuredto form a grille guard. Additionally, the push bar may comprise twogenerally horizontal tubular members that wrap around the front ends ofthe vehicle to form a wrap around brush guard that adds furtherprotection thereto. As will be recognized to those of ordinary skill inthe art, the push bar/grille guard is not limited to just lawenforcement vehicles but may be mounted to any vehicle for protectionthereof. As such, the push bar/grill guard may be mounted on off-roadvehicles or tow trucks.

[0004] The push bar is essential for proper law enforcement activities.It allows the law enforcement official to use his/her vehicle to pushstranded or damaged vehicles during emergency situations. The push barensures that the grille and bumper of the law enforcement vehicle willnot be damaged during such maneuvers.

[0005] The typical law enforcement vehicle is specially outfitted withpolice accessories such as emergency lights, police computer, heavy dutyengine and suspension. The bumper unit of a typical vehicle is formedfrom two members and is used for mounting the push bar thereon. Thefirst member is an outer, purely decorative fascia that integrates thestyling of the vehicle to the bumper unit. The second member is an innermetallic bumper disposed within the fascia and attached to the frame ofthe vehicle. The inner bumper is configured to absorb impacts andtherefore has the necessary strength and rigidity to mount the push barthereon. The bumper fascia is secured to the front of the vehicle andover the inner bumper via plastic push fasteners.

[0006] The conventional push bar is typically mounted to the innerbumper and bumper fascia of the law enforcement vehicle. As such,mounting and/or access holes must be drilled into the bumper and thebumper fascia. Therefore, the conventional push bar is difficult toinstall because the holes in the bumper and bumper fascia must beperfectly positioned and aligned. Typically, installation takes abouttwo hours and must be performed by a professional in order to insureproper installation.

[0007] Currently, law enforcement vehicles are replaced quite often dueto the wear from constant use. Therefore, after having been used, thelaw enforcement vehicle is re-sold at auction to the public. However,the conventional mounting of push bars necessitates the replacement ofthe bumper and bumper fascia when the push bar is removed prior toresale. The mounting holes drilled in the bumper weaken the bumper suchthat it is not safe for use. Additionally, the holes created in thebumper fascia necessitate replacement thereof because such holes detractfrom the vehicle's appearance. Therefore, when a law enforcement vehicleis re-sold, typically the vehicle's bumper and bumper fascia arereplaced. However, this is not desirable because it adds additionalexpense to the cost of the used law enforcement vehicle.

[0008] The present invention addresses the above-mentioned deficienciesin conventional push bar mounting methods by providing a mounting systemthat does not significantly damage the vehicle's bumper. Therefore, thepresent invention does not necessitate replacement of the vehicle'sbumper or bumper fascia and provides a system for mounting a push barthat is quick and simple to install. Additionally, the present inventionmay be adapted for installation of push bars and other accessories toprotect other types vehicles, not just law enforcement vehicles.

SUMMARY OF THE INVENTION

[0009] The present invention is a push bar mounting system for a vehiclebumper having a front and rear side. The system comprises a first,generally C-shaped front bracket formed complementary in shape to thebumper and having a first mounting tab. The first front bracket isgenerally disposed proximate to the front side of the bumper.Additionally, the system further comprises a first, generally planarrear bracket, formed complementary in shape to the rear side of thebumper, and having a second mounting tab. The first rear bracket isdisposed proximate to the rear of the bumper and attached to the firstfront bracket. Furthermore, in accordance with the present invention,there is provided a first generally vertical push bar membermechanically attached to the first and second mounting tabs and disposedproximate to the front of the vehicle so as to prevent damage theretoduring pushing maneuvers. The first and second mounting tabs areconfigured to project outwardly from exit openings in a bumper fasciathat covers the bumper. As such, the first mounting tab exits the fasciathrough an opening removed from the bumper fascia and the secondmounting tab exits through a grille opening of the fascia.

[0010] The push bar mounting system may further include a secondgenerally vertical push bar member that is attached to a second frontbracket via a third mounting tab and second rear bracket via a fourthmounting tab similar to the first push bar member. As such, the firstand second vertical push bar members comprise a protective push barsystem for the front of the vehicle.

[0011] The push bar mounting system constructed in accordance with thepresent invention may further include a first and second horizontalgrille guard member. As such, the first and second horizontal grilleguard members are attached to the first and second vertical push barmembers to form a protective grille guard for the front of the vehicle.

[0012] The present invention further includes a method of mounting apush bar to a vehicle bumper having a fascia cover. The method comprisesthe step of first removing the fascia from the bumper. Next, a sectionof the fascia is removed to provide an opening therein. Front and rearbrackets are attached to the bumper such that the bumper is disposedtherebetween. Both brackets provide mounting tabs for attaching agenerally vertical push bar thereto. Next, the bumper fascia isre-attached to the bumper such that one of the bracket mounting tabsprojects through the opening formed therein and the other mounting tabprojects through a grille opening of the fascia. Finally, a generallyvertical push bar member is attached to the mounting tabs in order toprotect the front of the vehicle from damage. It is contemplated in thepresent invention that a second vertical push bar member is attached tothe bumper in a similar fashion as the first member. Additionally, themethod of mounting the push bar to the vehicle may further comprisemounting a first and a second generally horizontal grille member betweenthe push bar members in order to form a grille guard.

BRIEF DESCRIPTION OF THE DRAWINGS

[0013] These as well as other features of the present invention, willbecome more apparent upon reference to the drawings wherein:

[0014]FIG. 1 is a perspective view of a push bar assembly, grille guardand wraparound brush guard mounted to a law enforcement vehicle;

[0015]FIG. 2 is a perspective view of a bumper fascia with push barmounting tabs projecting therethrough;

[0016]FIG. 3 is a perspective view of a set of push bar mountingbrackets;

[0017]FIG. 4 is a top plan view of the push bar mounting bracketsattached to an inner bumper;

[0018]FIG. 5 is a partial cut-away view of a push bar mounting bracket;

[0019]FIG. 6 is a side plan view of the push bar assembly.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0020] Referring now to the drawings wherein the showings are forpurposes of illustrating a preferred embodiment of the present inventiononly, and not for purposes of limiting the same, FIG. 1 perspectivelyillustrates a push bar assembly 10 mounted to the front of a lawenforcement vehicle 14. The mounting system described herein can beadapted for any type of vehicle 14 that is used to push other vehicles.Presently, the typical law enforcement vehicle is a Ford Crown Victoriaand the assembly 10 may be adapted for use on such vehicles.

[0021] The push bar assembly 10 protects the front of the lawenforcement vehicle 14 from damage that may be caused by pushing anothervehicle during emergencies or mechanical breakdowns. Typically, the lawenforcement vehicle will use two push bar assemblies 10 mounted on bothsides of a grille 16. As such, each push bar assembly 10 comprises atleast one generally vertical push bar member 18 configured to extendgenerally proximate the grille and/or front lights of the vehicle 14.The push bar member 18 is configured to protect the front of vehicle 14from damage and is therefore mounted in front of a decorative bumperfascia 12. The push bar member 18 extends in a generally verticaldirection such that the law enforcement vehicle 14 may push vehicleswith varying bumper heights without damage to either the law enforcementvehicle 14 or the vehicle being pushed.

[0022] In the preferred embodiment of the present invention, as seen inFIG. 1, two push bar assemblies 10 can be interconnected by a tophorizontal grille guard member 20 and a bottom horizontal grille guardmember 22 in order to protect the grille 16 of vehicle 14 from damage.The top grille guard member 20 is mechanically attached to the top endof each push bar member 18, while the bottom grille guard member 22 isattached near the middle of each push bar member 18. The grille guardmembers 20 and 22 are typically attached to each vertical push barmember 18 through the use of a threaded fastener in order to facilitateinstallation thereof or through a welded joint. The configuration ofeach of the vertical push bar members 18 and the top and bottom grilleguard members 20, 22 protect the grille area of the vehicle 14 fromdamage. Additionally, the bottom and top grille guard members 20, 22provide a location to install lights, winches, tow hooks and any othertype of emergency equipment and the push bar member 18 and grille guardmembers 20, 22 may be pre-drilled for installation of such accessories.Furthermore, as will be recognized by those of ordinary skill in theart, the top and bottom horizontal grille guard members 20, 22 mayextend around the front ends of the vehicle 14 to form a wraparoundbrush guard 24. As such, the grille guard members 20, 22 wrap around thefront of the vehicle 14 and are configured to prevent damage to thelights of vehicle 14.

[0023] In accordance with the preferred embodiment of the presentinvention, each push bar member 18 may be formed from two generallyplanar sections of metallic material attached perpendicular to eachother to form a generally T-shaped cross section. Therefore, as will berecognized, the two sections may be welded or attached to each otherthrough conventional means. A rubber strip 26 may be applied to avehicle contact surface of each push bar member 18. The strip 26 may beattached through the use of an adhesive or slid over the T-shaped crosssection as is commonly known. The rubber strip 26 prevents damage to thevehicle being pushed by the law enforcement vehicle 14. Additionally, inorder to protect the push bar assembly 10 from harsh environmentalconditions, all of the parts are fabricated with a rugged, black, powdercoat finish.

[0024] Referring now to FIG. 6, the push bar assembly 10 comprises afront bracket 28 and a rear bracket 30 and the push bar member 18mounted thereto. The front bracket 28 and the rear bracket 30 areattached to each other such that the brackets 28, 30 compress an innermetallic bumper 32 disposed behind the bumper fascia 12. The frontbracket 28 is provided with a top mounting tab 34 for attachment of thepush bar member 18 and similarly the rear bracket 30 is provided with abottom mounting tab 36 for attachment of push bar member 18. The innerbumper 32 is attached to the vehicle 14 in a conventional fashion andprotects the front of vehicle 14 from damage. The bumper fascia 12surrounds the inner bumper 32 with enough space therebetween such thatthe front and rear brackets 28, 30 may be attached to the inner bumper32 without deforming the bumper fascia 12.

[0025] As seen in FIG. 5, the front bracket 28 wraps around a front side38, a bottom wall 40 and a top wall 42 of the inner bumper 32 in agenerally C-shaped configuration. As such, the front bracket 28 isfabricated from a generally planar section of metallic material and isformed to be complementary to the exterior shape of the inner bumper 32.The top mounting tab 34 is a generally horizontal section of materialattached to the front mounting bracket 28 such that the top mounting tab34 projects outwardly from the front side 38 of the inner bumper 32 at aprescribed location. The top mounting tab 34 is formed with at least onemounting hole for attachment of the push bar member 18. The frontbracket 28 additionally comprises a top attachment portion 46 thatprojects rearward from the top wall 42 of inner bumper 32, and a bottomattachment portion 48 that projects downwardly from the bottom wall 40of inner bumper 32. Both the top and bottom attachment portions 46, 48comprise mounting holes formed therein for mounting the front bracket 28to the rear bracket 30.

[0026] The rear bracket 30 is formed from a generally planar section ofmetallic material such that it can abut a rear side 50 of the innerbumper 32. The rear bracket 30 comprises a top attachment portion 52 formounting the rear bracket 30 to the top attachment portion 46 of thefront bracket 28. The bottom mounting tab 36 of rear bracket 30 isgenerally vertical and formed such that it projects away from the frontside 38 of the bumper 32 at a prescribed height below the bottom wall40. The bottom mounting tab 36 is formed with at least one mounting holedrilled therein for attachment of the vertical push bar member 18.Furthermore, the rear bracket 30 is formed with a bottom attachmentportion 54 for mounting the rear bracket 30 to the front bracket 28.

[0027] As best seen in FIG. 3, the front bracket 28 is attached to therear bracket 30 through the use of threaded fasteners. As such the topattachment portion 46 of the front bracket 28 is attached through theuse of a bolt 56, washer 58 and nut 60 to the corresponding topattachment portion 52 of the rear bracket 30. Similarly, the bottomattachment portion 48 of the front bracket 30 is attached to thecorresponding bottom attachment portion 54 of the rear bracket 30. Thisattachment method allows the brackets 28, 30 to be rigidly attached tothe inner bumper 32 at a prescribed location without having to removenor drill such inner bumper 32. Therefore installation of the brackets28, 30 can be easily accomplished.

[0028] The inner bumper 32 of the illustrated vehicle 14 is curved suchthat a front portion 62 projects forward of the the ends 64. As such,when a front bracket 28 and a rear bracket 30 are mounted thereon, thetop mounting tab 34 and the bottom mounting tab 36 must be angled sothat the push bar member 18 is parallel to the front of the vehicle 14.Therefore, as seen in FIG. 4, the top and bottom mounting tabs 34 and 36are angled such that they are parallel to a longitudinal axis of thevehicle 14. As such, by angling the top and the bottom mounting tabs 34,36, two bracket sets 66, 68 are created for corresponding sides of thevehicle. As seen in FIGS. 3 and 4, the passenger or right-hand-sidebracket set 66 is created and a driver or left-hand-side bracket set 68is created by angling the mounting tabs 36, 34 toward the center portion62 of the inner bumper 32. The bottom mounting tab 36 of rear bracket 30is attached to an edge of the rear bracket 30 closest to the centerportion 62 of the inner bumper 32. However, as will be recognized bythose skilled in the art, the bottom mounting tab 36 may be attached toany edge of the rear bracket 30 so long as the bottom mounting tab 36projects forward from the inner bumper 32 at a prescribed location formounting the vertical push bar member 18 as will be explained in greaterdetail below.

[0029] In order to mount the push bar assembly 10 to the vehicle 14without substantial modification or damage thereto, the top and bottommounting tabs 34, 36 are configured to exit the bumper fascia 12 throughopenings therein. Therefore as seen in FIG. 2, the bottom mounting tab36 is configured to exit the bumper fascia at a prescribed locationwhereat a grille opening 76 is formed in the fascia 12. As such, thefascia 12 does not need to be modified for the bottom mounting tab 36.However, the bumper fascia 12 will need to be slightly modified toprovide an opening for the top mounting tab 34. A small horizontal exitopening 70 is created in the fascia 12 in order for the top mounting tab34 to project outwardly from the inner bumper 32 when the fascia 12 isplaced thereover. As such the top mounting tab 34 is configured to exitthe bumper fascia 12 at a location whereat the exit opening 70 is formedin a horizontal channel 72 for chrome trim 74 of the bumper fascia 12.Therefore, as seen in FIG. 2, a small section of the chrome trim 74 isremoved, as well as an underlying section of the bumper fascia 12.Removal of these sections allows the top mounting tab 34 to projectoutwardly from the bumper fascia 12 through the exit opening 70 createdthereby. With the top and bottom mounting tabs 34, 36 projectingoutwardly from the bumper fascia 12, the vertical push bar member 18 maybe installed thereon.

[0030] As seen in FIGS. 1 and 6, the vertical push bar member 18 isattached to the top and bottom mounting tabs 34, 36 via threadedfasteners. As such, vertical push bar member 18 comprises a horizontal,top mounting flange 78 that attaches to the horizontal top mounting tab34. The top mounting flange 78 comprises mounting holes positioned in alocation corresponding to the mounting holes in the top mounting tab 34.The vertical push bar member 18 also comprises a bottom mounting hole 80corresponding to the mounting hole in the bottom mounting tab 36.Therefore, the vertical member 18 is mounted to the top and bottommounting tabs 34, 36 at the top mounting flange 78 and the bottommounting hole 80 with threaded fasteners. As will be recognized by thoseof ordinary skill in the art, the top and bottom mounting tabs 34, 36may be configured to mount the vertical push bar member 18 in varyingways as long as the push bar member 18 comprises a correspondingattachment member.

[0031] The removal of a section of chrome trim 74 and bumper fascia 12are the only permanent modifications made to the vehicle 14 duringinstallation of the push bar member 18. As such, upon removal of thepush bar member 18, and the front and rear brackets 28, 30 for resale ofthe vehicle 14, the bumper fascia 12 will not need to be replaced. Sincethe opening 70 is formed in the channel 72 for the chrome trim 74, theopening 70 can be covered by replacing the chrome trim 74. The bumperfascia 12 is not structurally integral for the performance of the innerbumper 32, such that the exit opening 70 can be covered with trim 74without detriment to the safety of vehicle 14. Therefore, the only partthat will need replacement upon removal of the push bar mounting system10 and resale of the vehicle 14 is the chrome trim 74. The cost ofreplacing the chrome trim 74 is far less than replacing the inner bumper32 and the bumper fascia 12 and therefore is more economical upon resaleof the vehicle 14.

[0032] The push bar mounting system 10 is very simple to install inunder twenty-five minutes. First the bumper fascia 12 is removed fromthe vehicle 14 by detaching the plastic push fasteners securing thefascia 12 to vehicle 14. Next, the front and rear mounting brackets 28,30 are rigidly fastened to the inner bumper 32 using the threadedfastener 56, and corresponding washer 58 and nut 60. Both aright-hand-side 66 and a left-hand-side 68 set of brackets are installedon corresponding sides of the inner bumper 32. The front 28 and rear 30brackets fit over the inner bumper 32 such that the bumper 32 does notneed to be removed. The location where each of the top mounting tabs 34exit the bumper fascia 12 is determined and the exit opening 70 isformed therein for each left and right hand set of brackets 66, 68. Theexit opening 70 is formed by first cutting away about three inches ofthe chrome trim 74 at the prescribed location with a utility knife andthen cutting away the underlying fascia 12 in the trim channel 72. Theexit opening 70 must be formed within the trim channel 72 so that theopening 70 is not noticeable when the trim 74 is replaced for resale ofvehicle 14. The opening 70 must be formed on both the left-hand-side andthe right-hand-side of bumper fascia 12 if two push bar mounting systems10 are being used. The fascia 12 is then reinstalled on the vehicle 14with the lower mounting tab 36 projecting through a grille opening 76and the upper mounting tab 34 projecting through the exit opening 70formed in the fascia 12. Next, the vertical push bar member 18 isinstalled to the top mounting tab 34 and the bottom mounting tab 36 foreach set of mounting brackets 66, 68.

[0033] Additional modifications and improvements of the presentinvention may also be apparent to those of ordinary skill in the artsuch as adapting the push bar mounting system 10 for use on other typesof vehicles and with other types of accessories. Thus, the particularcombination of parts described and illustrated herein is intended torepresent only certain embodiments of the present invention, and is notintended to serve as limitations of alternative devices within thespirit and scope of the invention.

What is claimed is:
 1. A push bar mounting system for a bumper of a vehicle, said bumper having a front exterior and a rear exterior, said system comprising: a first front bracket formed complementary in shape to the front exterior and having a first mounting tab; a first rear bracket formed complementary in shape to the rear exterior and having a second mounting tab, the first rear bracket attached to the first front bracket such that the bumper is disposed therebetween; and a first elongate push bar member attached to the first and the second mounting tabs, the first push bar member disposed generally vertically in front of the vehicle to prevent damage thereto.
 2. The push bar mounting system of claim 1 wherein the first and second mounting tabs are configured to extend through a respective exit opening situated in a fascia associated with the bumper.
 3. The push bar mounting system of claim 2 wherein: the first front bracket is generally C-shaped; and the first rear bracket is generally planar.
 4. The push bar mounting system of claim 1 further comprising: a second front bracket formed complementary in shape to the front exterior and having a third mounting tab; a second rear bracket formed complementary in shape to the rear exterior and having a fourth mounting tab, the second rear bracket attached to the second front bracket such that the bumper is disposed therebetween; and a second elongate push bar member attached to the third and the fourth mounting tabs, the second push bar member disposed generally vertically in front of the vehicle.
 5. The push bar mounting system of claim 4 wherein: the second front bracket is generally C-shaped; and the second rear bracket is generally planar.
 6. The push bar mounting system of claim 4 further comprising a first generally horizontal grille guard member attached to the first and the second push bar members.
 7. The push bar mounting system of claim 6 further comprising a second generally horizontal grille guard member attached to the first and the second push bar members.
 8. The push bar mounting system of claim 7 wherein the first and second push bar members and the first and second horizontal grille guard members are configured to form a grille guard.
 9. The push bar mounting system of claim 4 wherein the first, second, third and the fourth mounting tabs are configured to extend through a respective exit opening situated in a fascia associated with the bumper.
 10. A method of mounting a push bar to a vehicle bumper having a fascia cover, comprising the steps: a) removing the fascia cover from the bumper; b) removing a section of the fascia to provide an opening therein; c) attaching a first front mounting bracket with a first mounting tab to a first rear mounting bracket with a second mounting tab such that the bumper is disposed between the first front and first rear brackets; d) attaching the fascia to the bumper such that the first mounting tab projects through the fascia opening and the second mounting tab projects through a grille opening of the fascia; and e) attaching a first generally vertical push bar member to the first and second mounting tabs.
 11. The method of claim 10 wherein: step (b) further comprises removing a second section of the fascia to provide a second opening therein; step (c) further comprises attaching a second front mounting bracket with a third mounting tab to a second rear mounting bracket with a fourth mounting tab such that the bumper is disposed between the second front and second rear brackets; step (d) further comprises attaching the fascia to the bumper such that the third mounting tab projects through the second opening and the fourth mounting tab projects through a grille opening of the fascia; and step (e) further comprises attaching a second generally vertical push bar member to the third and fourth mounting tabs.
 12. The method of claim 11 further comprising the step of: f) attaching a first generally horizontal grille guard member to the first and second vertical push bar members.
 13. The method of claim 12 further comprising the step of: g) attaching a second generally horizontal grille guard member to the first and second vertical push bar members.
 14. The method of claim 10 wherein said fascia of step (b) comprises a section of a fascia trim channel. 